Apparatus for protecting concrete and other masonry materials



Aug. 28, 1962 APPARATUS FOR PROTECTING CONCRETE AND OTHER MASONRY MATERIALS Filed Oct. 28, 1958 5 Sheets-Sheet 1 fil|ll|l III I mwU I IIIJ W wm G. c. DION 3,051,821

APPARATUS FOR PROTECTING CONCRETE AND OTHER MASONRY MATERIALS Aug. 28, 1962 5 Sheets-Sheet 2 Filed Oct. 28, 1958 G. C. DIQN Aug. 28, 1962 APPARATUS FOR PROTECTING CONCRETE AND OTHER MASONRY MATERIALS Filed Oct. 28, 1958 5 Sheets-Sheet 3 (5- C. DION Aug. 28, 1962 APPARATUS FOR PROTECTING CONCRETE AND OTHER MASONRY MATERIALS Filed Oct. 28, 1958 5 Sheets-Sheet 4 CONDUCTOR INSULATION BRAI D JACKET NICKEL-CHBOMIUN TINNED COPPER RED SILICONE RUBBER I T "12s Aug. 28, 1962 G. c. DION 3,051,821

APPARATUS FOR PROTECTING CONCRETE AND OTHER MASONRY MATERIALS Filed Oct. 28, 1958 5 Sheets-Sheet 5 United States Patent Office 3,051,821 Patented Aug. 28, 1962 3,051 821 APPARATUS FOR PROTEOTING CONCRETE AND OTHER MASONRY MATERIALS George C. Dion, Coraopolis, Pa, assignor to Noid Corporation, Coraopolis, Pa., a corporation of Pennsylvanra Filed Oct. 28, 1958, Ser. No. 770,071 2 Claims. (Cl. 219-46) The present invention relates in general to method and apparatus for protecting concrete and other masonry materials, and more particularly concrete and other masonry masses, against extreme cold and freezing temperatures during drying out and setting of the materials forming the masonry masses, to avoid the subsequent crumbling and crushing of said masses as a result of the presence of frost or ice during the drying out and setting of said materials to rigid state.

The procedure now most generally practiced for this purpose is to cover such materials and masses with tarpaulins of flexible material provided with ducts of cloth for conveyance of heated air or other gases from sources of heat to diiferent masonry areas under the tarpaulins. This latest procedure is more expeditious and more favorable for this purpose, from the standpoint of safety from fire hazards than obtains with the use of chemical mixes and with the ancient use of straw and open fires to provide the necessary heat, for avoidance of retention of moisture in the expanded form of frost or ice, in the masonry masses at the end of the setting period, usually seventy-two hours.

This duct heated tarpaulin system has the disadvantage, however, of being cumbersome and complex to maintain a uniform and even distribution of heat with avoidance of hot spots throughout the masonry masses, and requires for large installations high maintenance costs due to the necessity of having many operating personnel present throughout the usual 72 hour setting period to insure correct flow of heat at all times for the required purpose.

The primary object of the present invention is the provision of a novel systematic method and apparatus for effecting a like blanket protection of such masonry material and masses in a simpler, more economical and facile way, which reduces the number of operating personnel required to be in attendance during the 72 hour period, to one individual merely for checking the system to insure against and replace part failures. The system of the present invention is entirely automatic in operation and operable by readily available sources of electricity, or portable electric generators, is easily applied to the work and is not cumbersome or complex to roll up and be stored when not in use.

A further object of the invention is the provision of a method and apparatus as aforesaid which is of wider application and equally suitable for its greater ease and facility in protecting column base plates for structural steel, grouting machinery, wall bearing plates in beam pockets in masonry or concrete walls, bricklayers or masons swing-type scaffolds, as well as sidewalks, driveways, basement and garage floors.

A still further advantage of the invention is that the method and apparatus is also applicable to protection and drying out of concrete and cinder block's, tiles or brick, to prevent shrinkage or cracks, and is applicable to protection of bag cement, sand and gravel stockpiles.

Accordingly, the present invention comprises a method and apparatus employing a conventional type of thermoelectrical heated blanket, thermostatically controlled and detachably connectable at will to a source of AC. and DC electric current, mountable over the masonry materials and masonry masses thereof, prior to and during the setting for 72 hours, and readily and easily removable therefrom.

More particularly, the invention includes the specially designed blanket of this type as adapted and perfected as hereinafter described to better carry out the novel method and apparatus for protecting concrete and other masonry work, during the drying and setting periods, against extreme cold or freezing temperature which would result in the formation of expanded water in the form of frost and ice in the finally set masses.

In the accompanying drawings forming a part of this specification, there is shown, for purposes of illustration, the best mode of practicing and embodying the invention. The invention, however, is not limited in all its aspects to the best mode illustrated, since much of the advantage of the invention is attained by other forms of the conventional elements employed all of which are of themselves common, well known, and readily available. For instance, the blanket as shown While constituted of fiber glass insulation material, may be constituted of other equivalent thermal insulation materials, and the coils and covers for the thermal insulation material may comprise other known equivalents. Hence the invention in all its aspects is not confined to the specific uses, and the specific materials herein described as the best mode known to the inventor at this time.

Other objects and advantages of the invention will be apparent as it is better understood from the following description when considered in connection with the accompanying drawings illustrating the best mode of practicing the same.

FIG. 1 is a plan view, with parts broken away for ease of illustration, of a conventional type of thermoelectrical heating blanket as particularly devised to adapt it for especial use in practicing the novel method and apparatus for protecting masonry materials and settable masonry masses;

FIG. 2 is a vertical cross section taken on the line IIII of FIG. 1;

FIG. 3 is a vertical sectional view of the wooden form for an upright wall to be warmed up by the blanket thereon prior to pouring of concrete;

FIG. 4 is the same view but showing the wall with the concrete in place.

FIG. 5 is a side elevational view of the wall as shown in FIGS. 3 and 4;

FIG. 6 is side elevational view illustrating the method and apparatus as applied in combination with the setting and grouting of column base plates for structural steel and machinery;

FIG. 7 is a side elevational view illustrating the method and apparatus as applied in combination with wall bearing plates in beam pockets of brick or concrete walls;

FIG. 8 is a side elevational view illustrating the invention as applied to upright walls with swing type scaffolds;

FIG. 9 is an isometric view illustrating the application of the invention to extensive horizontal structure-s such as floors, sidewalks, and driveways;

FIG. 10 is an elevational view partly in section illustrating the invention as applied to columns;

FIG. 11 is an isometric view as applied to bulk products;

FIG. 12 is a sectional view of a conventional type of thermoelectric cable as used for supplying the heat for the masonry material;

FIG. 13 is a diagrammatic view of one type of conventional thermostat employed as a part of the invention.

T he same reference numerals are used for like parts in each of the several views.

Referring to the drawings, the conventional type of thermoelectrical heated blanket 9 employed to protect the aforesaid masonry mass and materials comprises in general the basic elements as usually employed for such blankets, comprising an inner mat of solid insulating material 10 with the usual electrical cable heating coils 11 therein and an enclosing cover 12 on opposite sides of the mat with a lead connection 13 from the coils to detachably connect with a source of electric power 14, which may be either AC. or DC. current, and a thermostat 15 in the circuit.

Preferably the blanket 9 comprises a mat with two onehalf inch thick layers of fiberglass, with the coils 11 laid in parallel lines intermediate the layers of fiberglass, and one and one-half inch diameter outwardly opening convective passages 16 extending from the coils 11 through one layer of the fiberglass and its adjacent cover 12 at six inch intervals, to open out to the surrounding atmosphere.

The covers 12 and mat layers 10 are stitched together by parallel rows 17 of stitches intermediate the parallel lines 18 of the coils 11.

The area containing the coils is bounded by overlapping marginal twelve-inch lap portions 19 of the covers on opposite sides of the mat, which margins are stitched together devoid of heating coils 11 and fiberglass 10, and are provided with grommets 20 for securing the blanket in place.

The top and bottom covers are also preferably composed of flame, water and mildew-proofed tarpaulin. The heating cable that forms the coil in the insulation layers is of the type having an inner conductor 21 of nickel chromium wire, covered with a layer of insulation 22 of silicone rubber, an intermediate layer 23 of braid of tinned copper, and an outer layer or jacket 24- of silicone rubber. The thermostat is of the type settable for maintaining a uniform temperature range of degrees within the blanket at degrees running from 30 to 110 F.

Referring to FIGS. 3 to 5, the invention is there shown as applied to an upright wall 25 to be formed of concrete 26. As seen in FIG. 3, the wooden wall form boards 27 are in braced position over a keyway 28 for the bottom 29 of the wall in an already set base formed of a concrete mass 30, and within the wooden form is shown the steel reinforcement 31 for the concrete of the wall. In accordance with the invention several of the aforesaid blankets are mounted over the entire wooden form in marginal overlapping relation, and held down on the form in place by strips 32 and weights 33. The thermostat 15 is inserted inside the form and set to maintain the blanket 9 within a uniform range of five degrees temperature, and the lead wire 34 for coils 11 is then set into operation with a source 14 of electric current. The system is thus maintained in operation on the form until the entire contents of the form, including the keyway, is warm enough to eliminate any frost or ice, and until the concrete is ready to be poured, at which time the top cover only is removed for pouring the concrete into the form, and the thermostat is moved to the outside of the form. After the pour is completed, the top cover is replaced and the thermostat is relocated under the blanket outside the wooden form, and then reset to the temperature required to maintain a solid material thermal insulating zone intermediate the wet concrete mass and the surrounding atmosphere at such a higher temperature, relative to an expected prevailing lower freezing temperature of said atmosphere, that freezing cannot occur, as a result thereof, in the freshly poured concrete mass.

The blanket is maintained in this position as shown in FIGS. 3, 4 and 5, until the concrete mass is dried and set, usually about 72 hours.

Referring to FIGS. 6 and 7, the invention as there shown as applied to column base plates 35 and grouting 36 in FIG. 6, and to wall bearing plates 37 and grouting 38 in FIG. 7. In FIG. 6, the grouting 36 is shown as applied to an existing concrete mat 39, and the column base plates positioned in place on the grouting. The setting and grouting of the column base plates for structural steel and for machinery must be done with utmost care and precision as the combined weights of structure and equipment bear on the grout and dry pack. Freezing would cause the same to crumble, and crush under the weight. As shown, the blankets 9 are easily applied to the dry pack and operate to warm the same before grouting. The blanket 9 is removed and grouting and plates installed and blanket re-installed over the complete assembly as shown in FIG. 6, and then the thermostat reset to operate for 72 hours in the same manner as described above in connection with FIGS. 3 to 5. The same procedure is used as applied to Wall bearing grouted plates as shown in FIG. 7, except in this case the blanket 9 is draped over or hung alongside the brick or concrete wall so as to cover the entire recess 40 in the wall 41, and the blanket 9 maintained uniformly at the required temperature by the thermostatic action in the same manner described in connection with FIGS. 3 to 5. The protection of such wall bearing plates from freezing in beam pockets 40 has always been a problem, which is easily solved by this system, since the blankets are easily applied and held at the desired uniform temperature electrically.

Referring to FIG. 8, the invention is there shown as applied to bricklayers or masons swing type scaffolds 8 which, when used in cold weather, usually are covered with tarpaulins 42. Open fires as usually needed, now can be eliminated by installing and operating the blanket 9, according to this invention, in between the plain tarpaulin 42 to keep the working area moderately warm during the days work, and at the end of the days work, other blankets 9 according to this invention, then can be placed over the top of the wall and set into operation to protect the wall from freezing at still lower temperatures, in the manner set forth above as to the other figures of the drawings. The same method of utilizing alternate tarpaulins 42 and blankets 9, as aforesaid is applicable to close in a building. The invention as described is applicable also between floors to protect the underside of concrete floors, as well as by laying the electric blanket 9 on top of floors above.

Referring to FIG. 9, the invention is there applied to extensive horizontal masonry areas 43, such as sidewalks, driveways, basement and garage floors. In such cases the wooden forms are covered and heated by the blanket 9 before pouring the wet concrete, in order to make certain that they are frost free. Then the concrete is poured while the parts of the form are uncovered only where necessary during the pour. The blanket 9 is then replaced and the thermostat reset to hold the insulation at the desired temperature. The heat is evenly distributed, and no hot spots develop such as occurs when heat is blown through ducts as heretofore done to prevent the freezing of the concrete.

Referring to FIG. 10, the invention is there applied to column forms 44, in which case the blanket 9 is wrapped around the form and the thermostat set into operation for the required time.

FIG. 11 shows the application of the invention to bulk objects 45, such as concrete and cinder blocks, the brick, bag cement, sand and gravel stocks. When these must be kept dry and frost free, to prevent shrinkage cracks, they are stacked with spacer elements 46 and surrounded by the marginally overlapped blankets 9 of insulation material of the solid type of fiberglass, and heated thermoelectrically under thermostatic control to temperatures preventing frosting or icing of the masonry materials as a result of colder temperatures in the surrounding atmosphere.

In operation the blankets 9 are applied over the forms for the masonry masses, before pouring, when concrete is the masonry material, and the thermoelectric coils 11 connected to a source 14 of electrical energy and the thermostats 15 set to warm the forms free of frost or ice. Thereafter, and also in the case of brickwork masonry or bulk masonry materials, the blanket 9 is mounted over the same and connected to the electricity source 14, and the thermostat 15 set :to operate at the range of temperature to heat the solid thermal insulation material to a temperature sufficient for continuous isolation of the masonry material from the cold of the surrounding atmosphere by a solid insulation zone held at such a higher temperature, usually 40 to 70 'F., relative to an expected prevailing lower freezing temperature of the surrounding atmosphere, that frosting and freezing cannot occur in the masonry material as a result of said cold atmosphere temperature. For concrete masonry masses to be dried for setting into rigid state, this insulation zone is maintained at a uniform temperature throughout for about 72 hours.

The invention as hereinabove set forth is embodied in particular forms and manners but may be variously embodied otherwise within the scope of the claims hereinafter made.

I claim:

1. Apparatus for protecting masonry material against extreme cold and fireezing temperature, comprising: a blanket comprising a flat inner mat of solid thermal insulation material with thermoelectrical heating cable in coils laid in the solid material intermediate the two opposite external surfaces of the mat; flame, water and mildew proof tarpaulin covers enclosing the opposite sides of the mat with marginally lapping extensions, devoid of insulation and cable coil-s, beyond the perimeter of the mat; convective passages opening outwardly from the coils through the solid insulation and one cover of the mat; an electrical lead connection to the coils for connection to a source of electricity; and a thermos-tat electrically connected in series with said coils.

2. Apparatus as claimed in claim 1 and in which the solid insulation material of the mat is fiberglass.

References Cited in the file of this patent UNITED STATES PATENTS 1,661,476 Haswell Mar. 6, 1928 2,021,513 Levine Nov. 19, 1935 2,023,887 Hood Dec. 10, 1935 2,031,098 Cenp et al Feb. 18, 1936 2,185,692 McCleary Jan. 2, 1940 2,529,914 Challenner Nov. 14, 1950 2,624,886 Herman Jan. 13, 1953 2,666,840 Poirier Jan. 19, 1954 2,706,767 Packchanian Apr. 19, 1955 2,719,213 Johnson Sept. 27, 1955 2,719,907 Combs Oct. 4, 1955 2,873,352 Franco Feb. 10, 1959 2,942,321 Pinter et a1 June 28, 1960 

